Platinum and palladium catalysts in catalyzed reactions



United States Patent PLATINUM AND PALLADIUM CATALYSTS IN CATALYZED REACTIONS Eugene F. Schwarzenbek, Montclair, N. J., assignor to M. W. Kellogg Company, Jersey City, N. J., a corporation of Delaware No Drawing. Application September 26, 1-951, Serial No. 248,471

Claims. (Cl. 196-50) This invention relates to improved catalytic reactions, and more particularly pertains to improved processes wherein a platinumor a palladium-containing catalyst is employed.

An object of this invention is to provide improved catalytic reactions utilizing platinum or palladium catalysts.

Another object of the present invention is to provide an improved method for catalyzing hydrocarbon conversion with a platinumor palladium-containing catalyst.

Still another object of this invention is to provide an improved catalytic process for altering the carbon-hydrogen ratio of a hydrocarbon.

A further object of this invention is to provide an. improved process for reforming naphthas.

A still further object of the present invention is to provide an improved method for hydroforming petroleum naphthas.

The present invention comprises a novel catalytic process in which the catalyst is obtained by depositing a metallic residue of platinum and/ or palladium on a carrier or supporting material, using a promoting agent selected from the group consisting of an alcohol and a ketone which has a water solubility of at least about 0.05% by weight at 70 F.

Catalysts prepared according to the present invention possess numerous outstanding advantages and have a wide field of utility. In general, it appears that these contact materials are suitable for any reactions which are susceptible to catalysis with platinum or palladium. They are useful in a variety of hydrocarbon conversion reactions, particularly those in which the hydrogen-carbon ratio is altered. Among the numerous reactions which lend themselves to catalysis by contact materials of the type disclosed herein are dehydrogenation, hydrogenation, hydrogenolysis, cracking, hydrocracking (i. e., cracking under hydrogen pressure), isomerization, oxidation, aromatization, cyclization, hydrodesulfurization, hydrocarbon synthesis, dealkylation, hydrodechlorination, dehydroxylation, alkylation, polymerization and hydrogen exchange systems. In general, these reactions may be carried out under the conventional reaction conditions of temperature, pressure, etc., with the catalysts described herein. However, in many instances the activity of the new con:- tact materials permits the employment of less severe conditions, especially lower temperatures and contact times, without any sacrifice in yield. A wide variety of organic compounds may be dehydrogenated including naphthenes, paraflins, alkyl radicals in aralkyl compounds, butene, sterols, glycerides, and many other organic compounds. By changing the reaction conditions in a known manner, these catalysts are also elfective for hydrogenating organic compounds in general, and especially fatty glycerides and 2,760,912 Patented Aug. 28, 1956 with these catalysts, paraffins and naphthenes are the most significant feeds from a commercial standpoint; but polyalkyl aromatics may be similarly treated, as exemplified in the catalytic transformation of o-Xylene to p-xylene. In addition to the more common cracking reactions, the contact materials of the present invention are especially suitable for cracking in the presence of hydrogen as in the hydroforming process in which the feed is customarily a low octane naphtha. In hydroforming with the catalysts of the present invention a substantial degree of sulfur removal occurs and the reaction may readily be shifted to favor hydrodesulfurization rather than reforming by changing the reaction conditions in a manner familiar to those skilled in the art. The synthesis of hydrocarbons from carbon monoxide and hydrogen in the presence of the new contact materials is also contemplated. In the field of oxidative reactions, numerous changes can be efiected with the present catalysts including, for example, the transformation of sulfur dioxide to sulfur trioxide, the formation of nitric acid and also of hydrazine from ammonia, the conversion of urea into hydrazine and the oxidation of hydrocarbons in general. An example of a catalytic hydrodechlorination reaction of current importance, which may be catalyzed in accordance with this invention, is that in which hydrogen converts trifluorotrichloroethane into trifluorochloroethylene and hydrogen chloride. The contact materials of the present invention are also suitable for the hydrogen exchange systems as exemplified by the hydrogenation of coal with decalin and tetra'lin. By reason of their aromatizing and cyclizing characteristics they are outstanding in preparing benzene, toluene and the like in substantial yields from parafiins and naphthenes and also for the production of more highly cyclized compounds such as naphthalene, anthracene and alkyl substituted derivatives thereof under suitable conditions. In addition, polymerization and alkylation reactions are responsive to these catalysts; for example, the polymerization of olefins and the alkylation of aromatic compounds.

The present invention is especially useful for the reforming or hydroforming of naphthas into gasoline stocks of improved antiknock characteristics. Many benefits result from hydroforming with my catalysts in comparison with known reforming catalysts, including those containing platinum. After partial deactivation due to the deposition of carbonaceous matter during hydroforming, the contact materials disclosed herein have been regenerafed several times by combustion in an oxygen-containing gas with substantially full restoration of activity. This adaptability to regeneration is extremely important as it permits a broad variety of feed stocks to be processed successfully, including those of substantial olefin or sulfur contents and/ or having end points considerably in excess of 400 F. This is not believed to be true of the presently used platinum-reforming catalysts which appear to be non-regeneratable and are thought to require a carefully prepared feed stock of low olefin and sulfur content and having a final boiling point well below 400 F. A further advantage of the present invention is that it is not limited to rather mild hydroforming conditions in order to minimize the formation of deactivating deposits on the contact material in the conversion reaction. No such concern over the feed to the catalysts of the present invention is necessary, as carbonaceous and sulfur-containing substances are readily removed during the regeneration operation. Moreover, severe hydroforming conditions may be freely used as required in the production of higher antiknock fuels. In addition to being superior to all known hydroforming catalysts in activity and the quantity of aromatics produced, superior flexibility and highselectivity have also been noted in comparison with other known platinum reforming catalysts, especially in the higher octane ranges, and the novel platinum-alumina catalysts are unmatched by regeneratable hydroforming catalysts in low production of carbonaceous deposits. Many economies in investment and operating costs'are realized in hydroforming with the novel contact materials as a result of the smaller reactor, smaller separate regeneration vessel in a continuous system, longer on- .stream period in a fixed bed system or lower regenerated catalyst replacement rate in a continuous system, and improved product selectivity.

The catalysts of the present invention are particularly adapted'for hydroforming naphtha stocks. In hydroforming naphtha or gasoline stocks with the catalyst disclosed herein, the conditions may be varied rather widely; thus temperatures of about 600 to about 1050 F. are suitable and the preferred range is from about 800 to about 950- F. Within these temperature limits weight space velocities of about 0.05 to about 10.0 pounds of naphtha per hour per pound of catalyst in the reaction zone may be employed advantageously; however, space velocities of about 0.25 to about 5.0 provide the best results. Hydrogen should be introduced into the hydroforming reactor at rates running from about 0.5 to about 20.0 mols of hydrogen per mol of hydrocarbon reactants. This hydrogen may be in admixture with light gaseous hydrocarbons. In fact, it is usually introduced by recycling the norm-ally gaseous products, chiefly hydrogen along with about 10% more or less of hydrocarbons containing 1-3 carbon atoms of the hydroforming reaction. The hydrogen serves an important function in maintaining the activityof the contact material by minimizing coke deposition thereon. While the total reaction pressure may be maintained at any value between about 50 and about 1000 pounds per square inch gauge (p. s. i. g.), the best results are obtained by holding the reaction pressure within the range between about 100 and about 750 p. s. i. g. In any exent, the hydrogen pressure should not be allowed to become so great under any given set of reaction conditions that destructive hydrogenation occurs, as this will result in a net consumption rather than a net production of hydrogen in the reaction.

The processes of this invention can be conducted as static or fluid beds of catalyst and the systems can involve a fixed bed or circulating bed. can be in lump, granular or finely divided form. Granular catalyst may have a particle size of about 0.1 to 10 'mm., average diameter, whereas the powdered or finely divided catalyst may have a particle size of about 5 to 200 microns.

The catalyst employed for the reactions discussed above is exceptionally suited for the purpose, because it is promoted in a manner which imparts greater activity to platinumor palladium-containing catalysts. The function of the promoting agent of this invention is not clearly understood, however, the resultant activity of the catalyst material prepared by employing the promoting agent clearly indicates that an excellent catalyst is obtained. Generally, the promoting agent includes a variety of classes of compounds, such as for example, primary, secondary and tertiary aliphatic monohydric alcohols, aliphatic dihydric alcohols, aliphatic tri-hydric alcohols, ketones of the aliphatic and aromatic type, aromatic alcohols, etc. The alcohols can be hydroxyl substituted hydrocarbon compounds or they can comprise substituted alcohols in which there are present groups, such as for example, amino, sulfhydryl, nitro, nitroso, halogen, alkoxy-alkyl, carbonalkoxy, etc. Among the aliphatic alcohols, it is preferred to employ the alkanols containing about 1 to 9 carbon atoms in the molecule. With respect to aliphatic polyhydric alcohols, it is preferred to employ those containing not more than l0 carbon atoms in the molecule. The ketones may comprise the aliphatic or aromatic type, however, it is preferred using the aliphatic ketones, particularly the alkanones containing not more than 4 carbon atoms in the molecule. It is to be noted In any case, the catalyst that in the case of the promoting agents, it is desired that they possess a water solubility of at least about 0.05% by weight at F.

For the purposes of this specification and the appended claims it is intended that water solubility of the promoting agent will be the minimum solubility just mentioned. Water solubility is important from the standpoint of obtaining uniform distribution of the promoting agent throughout the catalyst mass prior to calcination. The components of the catalyst prior to calcination may be in the form of a slurry or gel which contain suflicient amounts of water to provide for adequate distribution of the promoting agent. It is possible to employ a material having a lower solubility than indicated hereinabove, however, it will be found that less satisfactory results are produced with respect to catalyst activity. The exact function of the promoting agent is not known, however, it is preferred that the promoting agent is volatilized from the catalyst mass at a temperature of about or below the calcination point. This is desired in order to avoid the deposition of undesirable cracked products on the finished catalyst product. The following are specific examples of promoting agents which are useful for the purposes of the present invention: methanol, ethanol, propanol, butanol, pentanol, hexanol, heptanol, ethylene glycol, propylene glycol, glycerol, acetone, methyl ethyl ketone, methyl propyl ketone, phenols, benzyl alcohol, etc.

THE AMMINE COMPLEX PREPARATION The promoting agent of this invention can be used to provide highly active catalysts which are derived from various novel or known methods of preparation. A catalyst preparation which has been found to be particularly adapted to the improvements of the present invention comprises adding a platinum or palladium ammine complex to an adsorptive carrier material, such as for example, alumina gel and then drying and calcining the mass to a finished product. The platinum or palladium ammine complex is prepared from ammonia or substituted ammonia compounds, e. g., the amines, and a platinum or palladium compound. The methods for preparing the ammine complexes are readily known by those skilled in the art to involve complexing, a platinum or palladium compound, such as a salt, e. g., a halide, nitrate, sulfate, sulfite, nitrite, oxyhalide, etc., with ammonia or substituted ammonia, e. g., alkylamine, alkyldiamine, quinolines, pyridines, hydrazo compounds, hydroxylamine, etc. The platinum or palladium in the complex may have a coordination valence of 4 or 6. The ammine complexes may be soluble in the polar or non-polar solvent which is employed for facilitating the catalyst preparation, or such ammines can be colloidially dispersed in either a polar or non-polar solvent in the required quantities. In either case, the solution or suspension of amine complex should be employed in quantities which will provide adequate distribution of the complex throughout the entire catalyst mixture in the desired manner. However, it is preferred to employ the water soluble ammine complexes by reason that these compounds result in very effective types of catalysts. Specific examples of complexes which may be suitable for this invention include nitritodihydroxylaminoammineplatinous chloride, nitritoethylenediaminoammine-platinous chloride, nitritopyridinodiammine-platinous chloride, tetrahydrozinoplatinous chloride, dihydrazinodiammineplatinous chloride, tn'propylenediaminoplatinic chloride, nitritodichloroethylenediaminomethylaminoplatinic chloride, dichloroquatermethylaminoplatinic chloride, dichlorobisethylenediaminoplatinic chloride, chloronitritopyridinotriammineplatinic chloride, tetrahydroxylaminoplatinous chloride, hydroxylaminotriammineplatinous chloride, quatermethylaminoplatinous chloride, bismethylaminodiammineplatinous nitrate, dihydrazinodiammineplatinous chloride, quaterpyridinoplat- 'inous sulfate, bispyridinopalladic chloride, biethylenediaminopalladous chloride, etc. 7 5

The support or carrier material for the platinum or valumina, titania, zirconia, charcoal, pumice, .kieselguhr be produced by fusing bauxite withsodium carbonate and employing carbon dioxide as a precipitant. For the purposes of this invention a synthetic hydrated gel formed by precipitating a solution of an aluminum salt, for exam- ,ple, .aluminum chloride, withammonium hydroxide is preferred.

-In the preparation of the catalyst, it ispreferred that the alumina be mixed as a freshly prepared hydrate with the platinum or palladium. In thecase of alumina ,gel the preferred :procedure for dispersing the .platinum or palladium is topeptizethe slurry of the :gel

with acetic acid or any .other suitable agent-toapH of from about -3.0 to about 8.0 and preferably betweenabout 4.0 and 6.0, preferably before adding. the ammine complex. When the alumina :is to .be stored because of'processing considerations, it may be dried at-a temperature :belowabout 400 F. Theterm'alumina gel .is intended hereafter to include a wet or dry alumina whichis not soluble in water in the gel form and whichis derived from .gels or capable of formingsgels by suitable adjustment of zthelacidity.

The relative quantities of the platinum or palladium .amminecomplex and the carrier material are determined by the 'final composition of the catalyst which is desired. Ordinarily, the-quantity of metallic platinum 'or palladium in the final catalyst product ranges from about'0.01 to about 5% by weight. Therefore, the quantity of platinum .or palladium ammine complex which is combined with the adsorptive'carrier material is determined'on the basis of the desired quantity of metallic platinum or palladium .in the final catalyst composition. Likewise, the amount of adsorptive material will be determined by a difference.

For most practical purposes, the concentration of platinum and palladium in the catalyst product should be in the range of about 0.1 to 1% by weigh-tot themetal, because the benefits derived from higher quantities of platinum are usually not justified by thecost of the platinum mate- .rial used in preparing the catalyst.

After the ammine complex has been thoroughly mixed with the carrier material which can be in the form of a gel, a dried material, or a calcinedmateria-l and the pro- .moting agent of this invention, the mixture'is dried and :calcined. In the case of an alumina gel, the drying tem- I perature is not critical and usually drying can be'accomiplished by heating at a temperature notgreater than about 400 F. preferably 210 to 250 F. for aperiod ofabout to 50 hours. Alternatively, the slurry can be dried andcalcined by being placed in an oven which is maintained at the temperature in the order of at least about '600-700 F. It is preferred that the promotingagent of this invention is volatilized from the catalyst mass by the time the calcination temperature is reached. The calcination procedure is important, because the ammine complex is decomposed to metallic platinum or palladium. The decomposition of the ammine complex can take place at a temperature of at least about 400 F. Generally, it is important in the calcination procedure to avoid an excessively high temperature-because there is a tendency for the catalyst to become permanently deactivated. Therefore, it is the general practice'to calcinethe catalyst mass at a temperature of at least about 600 F. and a temperature not greater than about 1500 F.,'for a-period from about 2 to 6 hours. It is not desired to exceed a temperature of 1500" F. for calcination, unless a stabilizer such as silica gel is incorporated in the carrier. 'How- -ever, it ispreferred to calcine the mixture of carrier material, promoting agent, and the platinum or palladium .in a hydroforming process.

activating agent.

.ammine complex at a temperature between about 700 :F. ..and about 1 200" F. for about 3 to v6 hours. Calcination appears to be about the best method of reducing anammine complex. However, it is also contemplated to reduce the complex by passing hydrogen over the dry material at moderately elevated temperatures. Further the -metal may be deposited on the carrier material 'before drying .by the addition of a reducing agent, such as for example, hydrazine or citric acid, to the ammine complex. The catalyst product prepared in accordance with'the above method may be substantially free of combined halogen or it may contain combined halogen in amount of about 0.2 to about 8% by weight of the total product. In obtaining the desired halogen content for a catalyst which is prepared from aluminum chloride, the gel is washed with water or ammoniated Water until the halogen content of the Wash water is zero or negligible. Thereafter, it is preferred adding halogen in the form of :ahalogen halide, etc. in the'desiredproportion. Such a'technique lends to a more accurate control of the combined halogen in the catalyst product.

The presence of silica in the catalyst product-serves to stabilize the catalyst towards high temperatures, and .in addition,.it can cause the inhibition of.-cracking reactions The inhibition of cracking by silica is observed at low concentrations of silica in the order of about 0.05 to 15%, preferably about 1 to 10% by weight ofsilica basedon the total weight of the cata- 'lystproduct. The silicais added to the catalystas a gel in the preliminary steps discussed above preferably with the other carrier material. Ordinarily,.the other carrier material, e. g., alumina gel and the silica gel are combined in the desired relative amounts prior to mixing The improvements of the present invention can also be realized for a catalyst which is prepared by the'method comprising the decomposition of a compound of the metal selected from the class consisting of platinum and palladium to form a metallic residue'on'an a'dsorptive carrier material in the presence of a metal such as mercury, zinc or cadmium or a compound thereof. The salts of mercury,'zinc or cadmium, serve as an activating agent in producing a catalyst of substantially greater activity than catalysts which are prepared without the presence of the The activating agent may remain in the final catalyst in certain instances, however, preferably it is a volatile material which evaporates or decomposes,

either at or below the temperature at which the catalyst is calcined or at the operating temperature at which the catalyst is maintained under conversion or regeneration conditions.

The activating agent can be used in the form of an 'organicor inorganic compound of mercury, zinc or cadmium, or mixtures of the foregoing compounds. The

inorganic compounds of mercury, zinc or cadmium include the oxides, hydroxides and salts thereof. The inorganic salts of mercury, zinc and cadmium include, for example, the chlorides, chlorates, bromides, nitrates, sulfates, nitrites, sulfides, sulfites, carbonates, 'bicarbonates, oxychlorides, fluorides, iodides, phosphates, phosphites, etc. Specific examples of inorganic compounds of mercury, zinc and cadmium are mercuric bromide, mercuric chlorate, mercuric acetate, mercuric chloride, mercuric cyanide, mercuric nitrate, zinc acetate, zinc bromide, zinc chlorate, zinc hydroxide, zinc nitrate, zinc sulfide, cadmium acetate, cadium carbonate, cadmium hydroxide, cadium cyanide, cadmium iodide, etc.

The organic compounds of mercury, zinc and cadmium which are useful as activating agents include a variety of classes, such as for example, the salts of the aliphatic and aromatic carboxylic acids, the aliphatic and aromatic sulfur salts, as well as the aliphatic and aromatic'phosphorous acids, etc. Particularly useful compounds of mercury, zinc and cadmium are the aliphatic carboxylate salts such as those derived from the fatty acids, the carbonic acids, the thiocarbomc acids, etc.

vboxylic acids can be of the monoor polybasic type.

Examples of such salts are mercurous benzoate, zinc benzoate, cadmium benzoate, mercuric phthalate, zinc phthalate, cadmium phthalate, mercurous salicylate, zinc salicylate, cadmium salicylate, etc.

It is preferred that the activating agent volatilize from the catalyst mass at or before calcination temperatures.

In some instances the activating agent is not volatilized at such temperatures, consequently the calcination operation may be conducted under sub-atmospheric pressures in order to remove substantially all or completely the activating agent from the catalyst mass. Moreover, it is preferred to employ promoting agents which volatilize from the catalyst mass at a temperature not greater than about 1200 F.

Ordinarily in the preparation of the catalyst, the activating agent can be added to the carrier material prior to the addition of the platinum or palladium compound; or the activating agent can be added to the mixture of carrier and platinum or palladium compound; or the addition of the activating agent can be made to the platinum or palladium compound prior to mixing the carrier therewith. In adopting the preparation of this catalyst to the present invention, the promoting agent can be added to any one of the components or mixtures of two or more of said components. The quantity of activating agent employed is about 0.01 to about 10.0%, preferably about 0.5 to about 5.0% based on the weight of the carrier. For example, a mercury compound should be mixed with a carrier material e. g., alumina gel in such proportions as to produce a mercury to alumina dry Weight ratio of about 0.0001 to 0.1 or higher. In this type of a preparation, the action of the activating agent is not completely understood, although it produces an effect on the catalyst which greatly enhances its activity over any catalyst prepared in the same manner with the activating agent omitted. Whatever may be the change in the catalyst resulting from the introduction of the activating agent into the mixture of constituents from which the catalyst is manufactured, it is not necessary that the activating agent remain in the final catalyst prodnot. As a practical matter, it is preferred to employ activating agents which volatilize below about 1000 or 1050" F. and which will leave no apparent trace or residue in the finished catalyst.

In the preparation of the activated catalyst, the platinum or palladium is distributed on the carrier by employing initially a compound of a metal which will decompose to form metallic platinum or palladium at calcination temperatures. The desired form of starting material can be prepared by saturating an aqueous solution of chloroplatinic acid or chloropalladic acid with hydrogen sulfide. Other starting materials can be employed, such as for example platinum ammine complexes, chloroplatini-c acid ammonium and potassium chloroplatinates and chloroplatinites, the corresponding palladium compounds and the like. Those platinum or palladium compounds which metallic platinum or palladium content of the final catalyst should be from about 0.01 to about 5.0% by weight, preferably about 0.1 to about 1.0%. i

The carrier material for the activated catalyst is prepared in essentially the same manner as described hereinabove with regard to the catalyst obtained from platinum or palladium ammine complex compounds. As indicated hereinabove with respect to the preparation of the platinum or palladium amm-ine complex type catalyst, the final product may contain less than about 0.1% by weight on a dry basis of combined halogen. On the other hand, it is also contemplated by means of the present invention to obtain a final catalyst having a combined halogen content in the order of about 0.2 to about 8% by weight.

With respect to the above catalyst preparation, the promoting agent of this invention, viz, a water soluble alcohol or water soluble ketone can be incorporated into the catalyst mass by the following methods: 1) with the carrier material either before or after drying and/or calcination; (2) with the activating agent described above; (3) with the platinum or palladium compound; or (4) the promoting agent can be added to a mixture of any two or more of the components discussed above. After the activating agent, the platinum or palladium compound, the carrier material and the promoting agent have been thoroughly mixed, the mixture is dried and calcined. The drying operation can be conducted at a temperature of not more than about 400 F., preferably about 200 to 250 F. for a period of about 15 to 50 hours. Alternatively, drying can be accomplished by a flash technique which involves subjecting a slurry of catalyst mass into an oven which is maintained at an elevated temperature, for example, at least about 600-700 F. After drying the catalyst mass, it is calcined at a temperature of at least about 400 F., however, more usually at a temperature in the range of about 600 to about 1500 F., preferably about 700 F. to about 1200 F. and for a period of about 2 to 6 hours or more.

In the above type of catalyst an improvement in catalytic property is accomplished by incorporating small amounts of silica therein. It was observed that the presence of small amounts of silica in the catalyst inhibited cracking thereby providing a catalyst material which is unusually desirable for hydroforrning reactions. During the preparation of the catalyst, the silica can be introduced in the form of a silica gel which is combined with the carrier material, e. g., alumina gel, preferably before adding either the activating agent, the promoting agent and/or the platinum or palladium compound. The silica content which is found satisfactory for purposes of inhibiting cracking reactions is about 0.5 to about 15%, preferably about 1 to 10% by weight of the total catalyst product.

The improvements of the present invention can be also realized in the case of platinum or palladium catalysts which are prepared by methods other than those described above. Likewise, the catalyst may contain alumina as the carrier, either alone or in combination with minor or small proportions of silica in the amount of about 0.01 to about 15 preferably about 1 to 10% by weight.

Generally, the promoting agent of the present invention is incorporated into the catalyst mass by one of the following methods: (1) it is combined with the carrier material prior to mixing with the platinum or palladium compound with or without the activating agent; (2) by mixing the promoting agent with the platinum or palladium compound prior to mixing same with the other components of the catalyst mass; (3) mixing the promoting agent with the activating agent prior to the incorporation of same with either the carrier material or the platinum or palladium compound; or (4) mixing the promoting agent with a mixture of the catalyst components prior to the drying or the calcination operation. The amount of promoting agent employed is determined on the basis of the water which is present in the catalyst mass prior to subjecting same to a drying and/ or calcination operation.

Other methods of preparation involve, for example, catalysts prepared by: (1) the method of precipitating platinum or palladium onto a carrier, e. g., alumina as platinum or palladium oxide by boiling potassium chloroplatinate, etc., and then reducing the oxide with a suitable reducing salt; (2) the conversion of a chloroplatinic or suitable palladic acid with hydrogen sulfide to form a platinic or palladic sulfide slurry which is then mixed with the carrier, e. g., alumina gel, dried and calcined at elevated temperature; and other well-known methods of preparing a platinum or palladium type of catalyst are included within the scope of the present invention. Regardless of the method used in precipitating or depositing metallic platinum or palladium on the carrier, it is generally proposed obtaining a promoted catalyst having a platinum or palladium content of about 0.01 to about 5% by weight, preferably about 0.1 to 1% by weight, based on the total weight of the catalyst. The final catalyst can contain less than 0.2% by weight of combined halogen, e. g., fluorine or chlorine, or it may contain about 0.2 to 8.0% by weight of combined halogen. It is desirable to ordinarily use about 1 to about 50% by weight, preferably about to about 40% by weight of the promoting agent based on the weight of water which is present in the catalyst mass prior to subjecting the mass to a drying and/ or calcination operation. It is preferred that the promoting agent be volatilized substantially or completely from the catalyst mass at about the calcination temperature. However, it is included within the scope of this invention to have a small residue from the promoting agent in the final catalyst product. The exact nature of the promoting agent is not clearly understood, however, the effects observed in the use of a catalyst which has been prepared with a promoting agent clearly shows that the activity is substantially increased over those catalysts which are derived without the utility of a promoting agent.

After mixing or combining the components of the cat alyst mass including the promoting agent of this invention, the mixture is generally subjected to an initial drying operation which is accomplished at a temperature of not more than about 400 F., preferably about 200 to about 250 F. and for a period of about to about 50 hours. During the drying step when using a low boiling point promoting agent it is found that a substantial part or all of the promoting agent is vaporized or volatilized from the catalyst mass. Beneficial effects in catalyst activity are obtained even though the promoting agent is substantially all or completely removed from the catalyst mass at a relatively low temperature, such as during the drying operation. In other cases, where the promoting agent is less volatile, it remains in the catalyst mass for a longer period of time and usually until the calcination temperature is reached. It is not essential that the promoting agent be removed completely from the catalyst mass at the time of reaching calcination temperatures. It is also contemplated that part of the promoting agent be removed during the calcination operation, although it is preferred that substantially all of this agent is removed from the catalyst mass at the time of reaching the calcination temperature. This is desirable in order to avoid any undesirable effects from cracking the promoting agent at elevated temperatures.

Calcination is an important step in the method of producing the promoted catalyst because in this operation, the platinum or palladium compound is decomposed to metallic platinum or palladium on the carrier material. The conditions of calcination are important from the standpoint that all of the platinum or palladium compound should be decomposed to metallic platinum orpalladium and the metal should be distributed throughout the carrier material in a way which will produce the greatest catalytic activity. Generally, calcination is coni0 ducted at a temperature greater than about 400' F.,imore .usually in the range of about 600 to about 1500.? F., preferably about 700 to about 1200 F. The catalyst mass is held at the elevated temperature for a .period of about 2 to about 6 hours or more; whereas in the preferred temperature range the mass is calcined for about 3 to about 6 hours.

In order to more fully understand the nature of this invention, specific examples of the method of preparation of the catalysts of this invention are given hereinbelow. However, it should be understood that no undue limitations or restrictions should be imposed by reason-thereof.

Example I The alumina gel was prepared by dissolving 5682 grams AlCla'6H2O (1200 grams AlzOa) in 18 liters of water and adding 4400 cc. of concentrated NH4OH (28% NHa) and 2 liters of water. The pH after hour of stirring was 6.98 at 285 C. The gel was filtered and washed with ammoniated water until the filtrate from the tenth wash gave a very slightly positive chloride test. A final wash was made with water. The precipitate was slurried in 3 liters of water and analyzed 13.1% A1203 and 0.05% chlorine. The 9481 grams of slurry were peptized with 64 cc. of glacial acetic acid which was diluted with an equal part of Water. -The pH of the peptized slurry was 4.51 at 24 C.

The tetramine platinous chloride solution was made by dissolving 4.1 grams of platinous chloride in 350 cc. of concentrated NHiOi-l, by adding the aqua ammonia in aliquot portions and boiling. The resulting yellow solution was acidified with 35 cc. of glacial acetic acid to bring the pH to about 6, and then diluted with Water to 400 ml.

The Pt(NH3)4Cl2 solution was added dropwise to 4830 grams of the peptized alumina slurry while stirring. The mixture started to gel when about half of the ammine solution was added. An addition of 1.5 liters of butyl alcohol to the slurry was then made. The final pH was 5.41 at 255 C. The mixture was placed onto porcelain evaporating dishes and dried for about 50 hours at 240 F. in a Despatch oven. The catalyst dried to a white color with a layer of brownish yellow matter on the top surfaces. The dried catalyst was ground to a fine powder and then calcined for 3 hours at 1000 F. in a suitable furnace. 595 grams of catalyst were obtained which were pelleted into m; inch pills and recalcined for 3 hours at 1000 F. A volume of 550 cc. of catalyst weighed about 383 grams. The catalyst contained 0.42% platinum.

Example [I 5210 grams of AlCla-6H2O were dissolved in 141. of water and when mixed with 3.8 liters of concentrated ammonium hydroxide, the alumina gel was precipitated. 300 ml. of ammonia and 3 l. of water were added further to adjust the pH to 7.10 at 32 C. and yield a stirrable mass. After filtering this mass, the filter cakes were washed to remove chlorine'compounds by reslurrying with 13 l. of water and ml. of concentrated ammonium hydroxide for one hour and then filtering again. After 9 more similar washings only a faint chloride test was obtained in the filtrate. The washed alumina gel was peptized with 32 cc. of glacial acetic acid (0.1 mol CHsCOOH/mol AlzOs), which lowered the pH to 4.3.5 at 20 C.

The platinum ammine complex was prepared by dissolving 4.24 gm. of platinous chloride in 375 cc. of concentrated ammonium hydroxide. Thereafter about 5 ml. of glacial acetic acid was added to the mixture to obtain a pH of substantially 7. The ammine complex thus prepared was poured rapidly into the alumina and "the mixture stirred for one hour. Atthispoint the pH was observed to be 5.57 at 23 C., and the slurry displayed a tendency to set to a gel. The slurry was dried for 36 hours at 230240 F. in a porcelain dish in a small oven to produce 807 gm. of a dried solid having a yellow tint on the top of the white alumina. The dried mass was then ground to a size small enough to pass through a 40 mesh screen and then calcined for two hours at 1000 F. The 563 gm. of resulting material were grayish with small black specks throughout. After pelleting the catalyst, the pellets were calcined at 1000 F. for an additional 4 hours. The catalyst pellets were gray in color, speckled with black and had a platinum content of 0.47%.

Examples I and II above illustrated methods of preparing the catalyst by (1) using a promoting agent of the present invention and (2) preparing the catalyst in a similar manner without the use of the promoting agent, respectively. These catalysts were later tested under hydroforming conditions and the results are reported hereinbelow.

In the following examples, there is illustrated the preparation of a catalyst employing an alumina gel which is derived by a method other than What is employed in Examples I and II above, and with and without the use of a promoting agent of the present invention.

Example Ill The alumina prepared from reacting aluminum sulfate with concentrated ammonium hydroxide had the following composition:

Weight percent Ignition loss or volatile material at 1500 F 78.89 S04 0.7 Analysis of the ignited solid:

A1203 99.15 504 1.70 NazO 0.014 F6203 -a trace 1700 grams of the unignited alumina described above were slurried in 960 cc. of water for about 20 minutes using high speed stirring equipment. The pH of the thick slurry was 8.04 at 25 C. To the slurry was added 30 cc. of glacial acetic acid which had been previously diluted with an equal part by volume of water in order to peptize the alumina gel. After 15 minutes the peptized solution showed a pH of 4.64 at 28 C. An additional 3 cc. of the above described diluted glacial acetic acid was added to the slurry to lower the pH to 4.52 at 28 C. The total time for peptization was 45 minutes.

170 cc. of platinous tetra-ammine chloride solution, Pt(NH3)4Cl2, were added to the slurry of alumina in a dropwise manner over a period of about minutes. The platinum solution contained 0.01027 gm. of platinum per ml. The mixture became thick and after min. of stirring its showed a pH of 4.70 at 26.5 C. The slurry was stirred an additional 5 min. before adding 870 cc. of butanol, in a concentration which gave 1.5 l. of butanol per 600 gm. of alumina. The mixture thickened and after minutes of stirring the pH was 4.82 at 32 C. The stirring was continued for an additional 18 minutes; the vibrant soft gel was placed on a large porcelain evaporating dish and dried for a period of 64 hours in an Elconap oven at 230 F. The dried catalyst was essentially white, opaque and some brown color was observed on a portion thereof.

The dried catalyst was ground to a powder and weighed 457 grams. After calcination at 4000 F. for a period of 3 hours, the catalyst material was pelleted in "$4 in. size and calcined an additional 3 hours at 1000 F. The pellets were dark brown and slightly speckled and contained about 0.48% platinum.

Example IV 2400 grams of the unignited alumina described in Example III were slurried in 1530 cc. of distilled water to provide an alumina content of 12.6% after stirring for 7.5 hours. The slurry was very thick and it had a pH 12 of 7.92 at 30 C. The slurry was then peptized by adding 56 cc. of diluted acetic acid, which was prepared by diluting equal parts of glacial acetic acid and water. The resultant slurry had a pH of 5.42 at 38 C. A further addition of 34 cc. of diluted acetic acid as described above lowered the pH to 4.70 at 38 C.

The peptized slurry of alumina was combined with 244 cc. of platinuous tetra-ammine chloride solution, Pt(NH2)iClz, which was added dropwise to the alumina over a 5 minute period. After 22 minutes the pH was 5.01 at 38 C. and the slurry started to thicken. After an additional 8 minutes the thick homogeneous gel was transferred to a large evaporating dish and dried in an Elconap oven for about 64 hours at 240 F. The dried catalyst was white, opaque and glassy with a small amount of: yellow color on the surface thereof. The catalyst was then ground to a powder and calcined for 3 hours at 1000 F. The calcined catalyst was dark brown and containing black specks throughout. 510 grams of the catalyst were pelleted in in. pills and calcined for an additional three hours at 1000 F. The resultant pellets were light gray and speckled. The catalyst contained 0.49% platinum.

The catalyst of the above examples were tested by hydroforming a Midcontinent heavy naphtha having an initial boiling point of 230 F. and an end point of 428 F. This naphtha had an octane number (CFRM) of 30 and contained approximately 9% aromatics by volume. By reason of its relatively low naphthenic content and the high end point, this is regarded as a difficult hydroforming stock with a tendency to form relatively large coke deposits. The catalysts were tested on a laboratory scale using a fixed bed of approximately 475 grams of pelleted catalyst. The hydrogen was fed in a pure state at the rates indicated (S. C. F. B.) in the table, measured as standard cubic feet per barrel of oil feed (measured at 60 F. and 760 mm. mercury). The regeneration of catalyst was conducted by purging the catalyst with hydrogen after the catalyst became partially deactivated by the accumulation of carbonaceous deposits. The pressure on the system was released and then purged with nitrogen. The catalyst was then heated to 950 F. and air was introduced along with nitrogen. The concentration of air was regulated to produce a maximum temperature of 1050" F. in the catalyst bed. During this operation the temperature of various points in the bed was ascertained with two thermo-couples, one located in the upper part, and one in the lower part of the bed. The flow of nitrogen and air through the bed was continued for about /2 hour after the temperature dropped to about 950 F. Following another nitrogen purge, the system was again placed under hydrogen pressure for about 1 hour while the hydrogen rate and temperature was being adjusted before feeding the naphtha again.

TABLE I Catalyst Ex. I Ex. II Ex. III Ex. IV

Test N0 l 2 3 4 5 6 Operating Conditions:

Temperature, f F 900 903 898 900 900 900 Pressure, p. s. r. g 500 500 500 500 Space Velocity, Wo/

5, 090 4, 830 5, 380 4, 670 5, 227 4, 375 No. of Regenerations 2 1 1 Yields (Output Basis):

% O4 Reformate,

Vol. Percent 89. 7 91.0 92. 5 39. 8 93.5 91. 7 10# RVP Reformate,

Vol. Percent 82. 2 1 96. 5 1 99. 5 94. 0 98. 0 1 95. 6 Dry Gas, Wt. Percent. 11. 5 7. 4 5. 6 9. 2 7. 0 8. 7 Octane No. CFRM:

100% O4 Reformation" 94. 2 83. 0 75. 9 86. 3 81. 6 78. 8 10# RVP Reformate... 93. 7 84. 0 77. 8 86. 9 82. 4 79. 7

1 Extraneous butane added to reformate to obtain a 10# RVP product.

For purposes of comparison, Tests Nos. 1 and 4 clearly demonstrate the higher activity of the catalyst which is prepared with the use of a promoting agent of this invention. It is noted that in the case of Test No. 1 which employs a freshly prepared promoted catalyst, the rcsearch octane number of the total liquid product reported as 100% C4 reformate was substantially higher than in Test No. 4 which employs the unpromoted fresh catalyst. By means of Test-s Nos.2 and 3 which involve the same type of catalyst as in Test No. 1, it has been possible to determine the comparable space velocity of the catalyst of Test No. 1 in order to obtain the product distribution and octane number of the product as shown in Test No. 4. On this basis, the catalyst prepared in Example No; 1 is about 1.7 times as active as the catalyst which. is pre pared in accordance with Example No. 2.

It is also to be noted that in Test Nos. 2 and 3,'the I catalyst had undergone two and three regenerations prior to obtaining the data reported in the table. It should also be noted that in Tests Nos. 2 and 3, the space velocity has been increased to 2.01 and 3.0 respectively. At higher space velocities, it is to be expected that higher yields of reformate and lower octane numbers are obtained. However, notwithstanding the regeneration of the catalyst favorable product distribution is obtained as well as exceptionally good quality for the condition-s of operation. These tests demonstrate that the novel catalyst of this invention can be regenerated without undergoing any significant decrease in catalyst activity. This characteristic of the novel catalyst permits the use of feed stocks having higher boiling end points than has been the practice to use heretofore. Furthermore, it is possible to employ feed stocks having a higher sulfur content than has been permissible in view that the sulfur compounds can be removed from the catalyst by regeneration.

Tests Nos. 5 and 6 present a comparison between a catalyst which has been prepared by using a promoting agent of this invention and one which was prepared without the use of the promoting agent. The main diiference in the catalyst used in Tests 5 and 6 over the catalyst used in Tests 1, 2, 3 and 4 is that the alumina was prepared by a different method. From the data, it is apparent that the superiority of a catalyst which is prepared by the use of a promoting agent will be obtained notwiflistanding any difierences in the method by which the alumina is derived. In Test No. 5 the total liquid product including the butanes, which is designated as 100% C4 reformate is higher than the yield in a similar product obtained in Test No. 6. Furthermore, the octane number of this product in Test No. 5 is higher than the corresponding product in Test No. 6. Clearly, therefore, a catalyst prepared by the use of a promoting agent increases the yield of the product and is more selective in the type of reactions which take place during the hydroforming operation.

Having thus illustrated the present invention by reference to specific examples, it should be understood that no undue limitations or restrictions should be imposed by reason thereof.

I claim:

1. A process which comprises subjecting a hydrocarbon under suitable conversion conditions to contact with a catalyst comprising a catalytic element selected from the group consisting of platinum and palladium on a porous carrier material, which catalyst is prepared by combining a hydrous carrier material, an ammine complex of a metal selected from the group consisting of platinum and palladium and a water soluble promoting agent having a water solubility of at least about 0.05% by weight at F. selected from the group consisting of an alcohol and a ketone, and then heating the mixture to efiect the decomposition of the said compound and thus produce a metallic residue on porous carrier material.

2. The process of claim 1 wherein the promoting agent is an alcohol.

3. The process of claim 1 wherein the promoting agent is a ketone.

4. The process of claim 1 wherein the promoting agent is an alkanol and the carrier material is alumina.

5. The process ofv claim 1 wherein the promoting agent is an alkanone and the carrier material is alumina.

6. A reforming process which comprises subjecting a naphtha fraction under suitable reforming conditions to contact with a catalyst comprising a catalytic element selected from the group consisting of platinum and palladium on a porous carrier material, which catalyst is prepared by combining a hydrous carrier material, an ammine complex of a metal selected from the group consisting of platinum and palladium and a water soluble promoting agent having a water solubility of at least about 0.05% by Weight at 70 F. selected from the group consisting of an alcohol and a ketone, and then heating the mixture to effect the decomposition of the ammine complex and thus produce a metallic residue on porous carrier material.

7. The process of claim 6 in which the promoting agent is an alkanol.

8. The process of claim 6 in which the carrier material is alumina and the promoting agent is an alkanol.

9. A reforming process which comprises subjecting a naphtha fraction under suitable reforming conditions to contact with a catalyst comprising platinum on alumina gel, which catalyst is prepared by combining a platinum ammine complex, a hydrous alumina gel, and a water soluble alkanol having a water solubility of at least about 0.05% by weight at 70 F. and then heating the mixture to effect the decomposition of the ammine complex and thus produce a metallic residue on porous alumina gel.

10. A reforming process which comprises subjecting a naphtha fraction under suitable reforming conditions to contact with a catalyst comprising platinum on porous alumina gel, which catalyst is prepared by combining a hydrous alumina gel, platinous tetraammine chloride and butanol, and heating the mixture to eifect a decomposition of the platinum compound and thus produce a metallic residue on porous alumina gel.

References Cited in the file of this patent UNITED STATES PATENTS 1,956,585 Oglesby et a1. May 1, 1934 2,461,959 Brandon Feb. 15, 1949 2,479,110 Haensel Aug. 16, 1949 2,486,361 Nahin et a1. Oct. 25, 1949 2,611,749 Haensel Sept. 23, 1952 2,623,860 Haensel Dec. 30, 1952 2,623,861 Haensel Dec. 30, 1952 FOREIGN PATENTS 343,285 Great Britain Feb. 19, 1931 594,463 Great Britain Apr. 11, 1942 

1. A PROCESS WHICH COMPRISES SUBJECTING A HYDROCARBON UNDER SUITABLE CONVERSION CONDITIONS TO CONTACT WITH A CATALYST COMPRISING A CATALYTIC ELEMENT SELECTED FROM THE GROUP CONSISTING OF PLATINUM AND PALLADIUM ON A POROUS CARRIER MATERIAL, WHICH CATALYST IS PREPARED BY COMBINING A HYDROUS CARRIER MATERIAL, AN AMMINE COMPLEX OF A METAL SELECTED FROM THE GROUP CONSISTING OF PLATINUM AND PALLADIUM AND A WATER SOLUBLE PROMOTING AGENT HAVING A WATER SOLUBILITY OF AT LEAST ABOUT 0.05% BY WEIGHT AT 70* F. SELECTED FROM THE GROUP CONSISTING OF AN ALCOHOL AND A KETONE, AND THEN HEATING THE MIXTURE TO EFFECT THE DECOMPOSITION OF THE SAID COMPOUND AND THUS PRODUCE A METALLIC RESIDUE ON POROUS CARRIER MATERIAL. 